Tufting apparatus for the manufacture of
carpets. rugs, and the like

ABSTRACT

YARN BITS ARE CUT FROM YARN STRANDS AND PNEUMATICALLY TRANSPRTED (BY SUCTION) TO BIT-LOADING STATIONS WHERE THEY ARE POSITIONED BY STOP MEANS FOR TRANSFER TO A BACKING LAYER BY BIT-APPLYING ELEMENTS AS PROVIDED BY NEEDLES, NARROW BLUNG-EDGES BLADES, OR SINGLE (WIDE) BLUNT-EDGED BLADE.

Aug. 10, 1971 sPANEL EIAL 7, Re. 27,155

. TUPTING APPARATUS FOR THE MANUFACTURE OF CARPETS| RUGS, AND THE LIKE Original Filed Oct. 23, 1965 18 Sheets-Sheet. ,1 V

IZA

Aug. 10, 1971 SPANEL ETAL Re; 27,165

TUFTING APPARATUS FOR'THE MANUFACTURE OF CARPE'I'S, HUGS, ANDTHE LIKE Original Filed ,Oct. 23. 1965 18 Sheets-Sheet I Aug. 10, 1.11 SPANEL ETAL Re. 27,165

TUF'TING APPARATUS FOR. THE MANUFACTURE OF CARPETS. BUGS. AND THE LIKE J Original Filed Oct. 23, 1965 18 Sheets-Sheet 3 A. N. SPANEL TUFTING APPARATUS FOR THE MANUFACTURE OF CARPETS, RUGS, AND THE LIKE Original Filed Oct. 23, 19 65 18 Sheets-Sheet 4 v N. SPANEL ETAL TUFTING APPARATUS FOR THE MANUFACTURE OF CARPETS, V HUGS, AND THE LIKE Original Filed Oct. 23, 1965 18 Sheets-Sheet 5 Aug. 10, 1971 SPANEL EI'AL Re. 27,165

TUFTING APPARATUS FOR THE MANUFACTURE OF CARPETS, HUGS, AND THE LIKE Original Filed Oct. 23, 1965 18 Sheets-Sheet 6 Fig. I24

Aug. 10, 1'97] SPANEL ETAL Re. 27,-l65

TUFTING APPARATUS FOR THE MANUFACTURE OF CARPETS, BUGS, AND THE LIKE I v Original Filed Oct. 23, 1965 18 Sheets-Sheet 7 Fly. 125 ,66 1

Aug. 10, 1-911 ANSPANEL EIAL Re, 21,165

TUF'IING APPARATUS FOR THE MANUFACTURE OF I CARPETS, HUGS, AND THE LIKE Original Filed Oct. 25, i965 l8 Sheets-Sheet 8 A. N. SPAN EL ETAL Re. 27,165 TUFTING APPARATUS FOR THE MANUFACTURE OF 'CARPEI'S, BUGS, AND THE LIKE 7 Original Filed Oct. 23, .1965 '18 Sheets-Sheet 9 Aug. 10,

Re.y27,165

A. N. SPA NEL ETAL TUFTING APPARATUS FOR THE MANUFACTURE OF Aug. 10,1971

' CARIPETS, BUGS, AND THE LIKE Original Filed Oct. 23, 1965 18 Sheets-Sheet 10 g- 10,1971 A N. SPANQEL ETAL Re. 27,165

{I'UFTING APPARATUS FOR THE MANUFACTURE OF GARPETS, BUGS, AND THE LIKE Original Filed Oct. 23, 1965 18 Sheets-Sheet -11 Aug. 10, 1 971 A. N. SPANEL F-TAL TUF'I'ING APPARATUS FOR THE MANUFACTURE OF CARPE'I'S, RUGS, AND THE LIKE Original Filed Oct. 23. 1965 18 Sheets-Sheet 12 Aug. 10, 1971 A. N. SPANEL EI'AL TUFTING APPARATUS FOR THE MANUFACTURE OF CARPETS, RUGS, AND THE LIKE Original Filed Oct. 23, 1965 18 Sheets-Sheet 13 Aug. 10, 1971 -A. N. SPAN ELv TUF'TING APPARATUS FOR THE RPETS, RUGS, AND

Original Filed octfzs, 1 5

ETAL' Re. 27,165

.MANUFA URE OF THE 18 Sheets-Sheet 14 Fig. /9

Aug. 10, 1971 YETAL K Re. 27,165

v TUFTINGAPPARATUS FOR THE MANUFACTURE OF CARPETS, RUGS, AND THE LIKE Original Filed Oct. 23, 1965 18 Sheets-Sheet 15 Fig.20

Aug. 10, 1971 SPANEL ETAL 126,211.65 7

- TUF'TING APPARATUS FOR THE?- MANUFACTURE OF CARPETS, BUGS, AND THE LIKE Original Filed Oct. 23, 1965 18 Sheets -Sh'eet 16 Aug. 10, 1971 SPANEL EIAL v Re. 27,165

'IUF'IING APPARATUS FOR THE MANUFACTURE OF I PET THE LI CAR 5, BUGS, AND KE Original Filed Oct 25. 1965 18 Sheets-Sheet 17 9 24 I Fig.22B V "22A am 103 Aug. 10, 1971 SP N L EI'AL Re. 27,165

, TUFTING APPARATUS FOR THE MANUFACTURE OF CARPETS, RUGS, AND THE LIKE Original Filed Oct. 25. i965 18 Sheets-Sheet 18 United States Patent Office Re. 27,165 Reissued Aug, 10,1971

27,165 TUFTING APPARATUS FOR THE MANUFACTURE OF CARPETS, RUGS, AND THE LIKE Abram N. Spanel, 344 Stockton St., Princeton, NJ. 08540, and Loy E. Barton, Bradenton, Fla.; said Barton assignor to said Spanel Original No. 3,387,577, dated June 11, 1968, Ser. No. 503,342, Oct. 23, 1965. Application for reissue Sept. 17, 1969, Ser. No. 866,416

Int. Cl. Dc 15/16 US. Cl. 112-79 38 Claims Matter enclosed in heavy brackets appears in the original patent but forms no part of this reissue specification; matter printed in italics indicates the additions made by reissue.

ABSTRACT OF THE DISCLOSURE Yarn bits are cut from yarn strands and pneumatically transported [by suction] to bit-loading stations where they are positioned by stop means for transfer to a backing layer by bit-applying elements as provided by needles, narrow blunt-edged blades, or a single [wide] blunt-edged blade.

This invention relates to mechanisms and methods for manufacturing carpets, rugs, pile textiles and the like by application of yarn-bits to a backing layer in location and color to reproduce any desired pattern.

In accordance with the present invention, the bitapplying elements of a tufting machine (specifically the needles, for example), are supplied in each cycle of the machine with yarn-bits of color and position, to reproduce the corresponding line of a desired pattern by a pneumatic transmission arranged specifically comprising at least one pair of associated guide and magazine structures. Each magazine structure has an array of passages respectively forming part of a path for pneumatic transmission of a yarn-bit to a corresponding needle or other bit-applying element. Each guide structure or means for receiving the ends of yarn strands has an array of similarly spaced passages for threading, in a repeated color sequence, with the yarn strands; the number of colors in each sequence should be not less than, and is preferably equal to, the total number of colors required by all lines of the pattern. The number of yarn passages, per guide structure, should preferably exceed the number of needles to be supplied therefrom to accommodate an additional color sequence of yarn strands.

During a cycle of the machine as used for two or more color operation, each passage of the magazine effectively scans, step-by-step, a complete color sequence of the guide-structure passages. For each step position of the scan, the magazine passages are each in alignment with a guide-passage corresponding with that step position and independent feed-means for the yarn strands are selectively controllable in accordance with patern requirements so that one or more or none of the magazine passages receive a yarn end fed from the ten aligned guide passage. In the interval between successive scan steps and after the time for operation of the feed-means, all yarn strands then extending between the guide and magazine structures are severed, as by timed knife means, so to leave yarn-bits of selected color in predetermined passages of the magazine.

During the machine-cycle, the yarn bits are transferred from the magazine by pneumatic means applied to hit transfer tubes, each having a receiving end aligned with a magazine passage and a discharge end adjacent the bitloading position of the corresponding bit-applying element. In one arrangement using needles for applying the bits, the yarn-bits are centered, as by reciprocable pneumatic stops before movement of the needles from loading position and a shutter valve normally sealing a vacuummanifold for the discharge ends of the transfer tubes is retracted to permit passage of the loaded needles from their loading position, through the backing layer, and then back to loading position. In another arrangement using needles for applying the yarn-bits, the eye ends of the empty needles pass through the backing layer to the bit-loading position, and after loading are returned through the backing layer for transfer of the bits thereto.

The invention further resides in a tufting machine having features of construction, combination and arrangement hereinafter described and claimed.

For a more detailed understanding of the invention, reference is made to the following description of preferred methods and apparatus and to the accompanying drawings in which:

FIG. 1 is a flow diagram illustrating the yarn and backing-layer paths and identifying components of the preferred apparatus;

FIGS. 1A and 1B are explanatory figures referred to in discussion of the tufting operation;

FIG. 2 schematically and in perspective illustrates the yarn-feed capstan of FIG. 1 and associated drive mechanism;

FIG. 3 schematically and in perspective illustrates one of the resser-feet of FIG. 1 and its drive mechanism;

FIG. 4 schematically and in perspective illustrates the yarn cut-0d knife of FIG. 1 and associated drive mechanism;

FIG. 5 schematically and in perspective illustrates a yarn-bit magazine of FIG. 1 and mechanism for effecting its linear motion;

FIG. 6 schematically and in perspective illustrates the magazine of FIG. 5 and mechanism for effecting its lateral motion;

FIG. 7 schematically and in perspective illustrates a suction control valve of FIG. 1 and its operating mechanism;

FIG. 8 schematically and in perspective illustrates a bit-centering stop of FIG. 1 and its operating mechanism;

FIG. 9 schematically and in perspective illustrates the shutter-valve of FIG. 1 and its operating mechanism;

FIG. 10 schematically and in perspective illustrates the needle-bar of FIG. 1 and its operating mechanism;

FIG. 11 schematically and in perspective illustrates a pin roll of FIG. 1 and its driving mechanism;

FIGS. 12A and 12B jointly provide a front elevational view of a tufting machine incorporating mechanisms schematically shown in FIGS. 1 to 11 with parts omitted for clarity of illustration;

' FIG. 13 is a side elevational view of FIG. 12A as viewed from the left;

FIG. 14 is a rear elevational view of mechanism shown in FIG. 13;

FIG. 15 is a side elevational view of FIG. 12B as viewed from the right;

FIG. 16 is a rear elevational view of mechanism shown in FIG. 15; I

FIG. 17 is a detail view, on enlarged scale, of the resser-foot mechanism and some associated components;

FIGS. 18A and 18B are detail views, on enlarged scale, of the drives of the needle-manifold valve, the bit stops and the shutter-valve of the needle manifold;

FIGS. 19 and 20 are front and side elevational views, on enlarged scale, of part of a bank of control solenoids for the yarn-feed mechanisms;

FIGS. 21A-21D are explanatory charts referred to in discussion of various modes of operation of machines embodying the invention;

FIGS. 22A-22D illustrate the construction and steps of operation of a modified needle-loading and bit-applying arrangement;

FIGS. 23A and 23B schematically illustrate, in side elevation, the construction and steps of operation of another loading and bit-applying arrangement; and

FIGS. 24 and 25 respectively illustrate, in front elevation, multi-blade and uni-blade constructions suited for the bitapplying arrangement of FIGS. 23A, 23B.

Referring to FIGS. 1 and 3, the magazine has a longitudinal row of spaced chambers 11 each with its discharge end in alignment with the receiving end of a bit-transfer tube 12, serving as a pneumatic communication means. The discharge end of each of tubes 12 is adjacent the path of a corresponding one of the forked tutting needles 13 carried by a reciprocable needle-bar 14. While'each needle is at rest at the top of its stroke,'a yarnbit B is pneumatically delivered to it from the corresponding transfer tube 12 and centered (FIG. 1A). The suction system hereinafter described in detail is illustrative of one form of pneumatic means for producing a differential of pressure for transport of the yarn-bits, it being understood that other forms of pneumatic means may be utilized. During the subsequent down-stroke of the needles, the ends of the yarn-bits in them are pushed through the backing layer L (FIG. IE) to project from the lower face of the layer. In other words, during the subsequent down-stroke of the needles, the centered bits in the double or forked needles are pushed through the backing layer L (FIG. 1B) to form initially a vertical U which is held by a portion of the backing layer straddled by the forked needles. For continued downward motion of the needles, the free ends of the bit ride out of the eyes of the needles before the end of the down-stroke (FIG. 1B) to form an inverted U. The empty needles return to their original position, each to receive another yarn-bit and the backing layer L, with its new line of tufting, is advanced one step in readiness to receive the next line of inverted U tufts.

In the interval between successive reciprocations of the needle-bar, as effected by the one-time shaft 25, each of the chambers '11 of magazine 10 is loaded with a yarnbit B cut by knife 15 from a yarn strand S, whose end positioned by a corresponding passage 16 in guide means or structure 17, is opposite the receiving end of the chamber to serve as means for receiving ends of yarn strands. Each yarn strand S is looped (FIGS. 1 and 2) about a series of one or more capstan drums 18 between its supply spool 19 and its guide passage 16. Between the capstan and guide passage 16, the strand S passes beneath a reciprocating presser-foot 20. When a bit-length of yarn is to be fed from a spool 19, the associated presserfoot is permitted to drop, in response to a command signal, for engagement with strand S at the beginning of a forward feeding stroke. The resulting tension on the yarn tightens the yarn loop on the capstans, so to pull an additional length of yarn from the spool. The resulting slack in the yarn strand in front of presser-foot 20 is taken up by suction supplied, as later described, through the magazine chamber 11. In consequence, a bit-length of yarn is pulled through passage 16 in the guide 17 and into the chamber 11.

In a modification of the strand-feed arrangement just described, the forward motion of the presser-foot 20 and the mechanism for effecting such forward motion are omitted. In such modified feed arrangement, suction applied through the magazine chamber is effective to tighten the strand as looped over the capstans; the element 20 normally engages the yarn strand and is lifted therefrom when that strand is to be fed to a magazine chamber. The length of the bit out from the end of the strand received by the magazine chamber may be controlled either by presetting the interval for which the cutter 15 opens the suction path from the magazine to the yarn guide or by presetting the interval for which the presser-foot 20 is up while the cutter 15 has opened such suction path.

Assuming that a command signal has been given to supply a bit-length of yarn from a particular spool 12 to the magazine chamber 11 for a particular needle, such bit-length is cut upon conclusion of the aforesaid feeding operation by a timed movement of the knife 1'5. The yarn-bit so cut off and left in the magazine is transferred to the corresponding needle by suction applied to its transfer tube 12 via the manifold 21. The timing of the bit-transfer suction is controlled by valve 22. The yarn-bit B as propelled from the delivery end of tube 12 into the then aligned eyes of the forked needle (FIG. 1A) is preferably centered by a reciprocable stop 23. After delivery of a yam-bit to needle 13, the shutter 24, which seals off the needle passages in the bottom of manifold 21, is retracted so to permit unobstructed movement of the needle first through the backing layer L and then back to its original position.

Although it is possible to use a single magazine for all needles, it is desirable principally for economy of space to use two or more magazines. In the particular tufting machine herein illustrated and described, two magazines 10 and 10A are used. The transfer tubes 12 from the upper magazine 10 extend from its chambers 11 to say the odd-numbered tufting needles and the transfer tubes 12A from the chambers of the lower magazine 10A extend to the even-numbered tufting needles. Both sets of transfer tubes connect to the common suction manifold 21, each adjacent its corresponding tufting needle. The yarn-feeding and cutting mechanisms associated with the lower magazine are the same as for the upper magazine and are identified by the same reference characters plus the suffix A to avoid unnecessary repetition of their description.

A suitable mechanism for driving the yarn-feed capstan 18 is schematically shown in FIG. 2. Because of the horizontal space needed by the yarn strands on a capstan, several capstans may be used. Each capstan then has a groove for each thread of yarn. The capstan shaft 30 is driven via sprocket 31, chain 32 and sprocket 33 from cam shaft 34, which in turn is driven via gear 35, idler gear 3 6 and gear 37 from shaft 3 8. The yarn-guide capstan drum 39 adjacent the capstan 18 is driven by gears 41 on their respective shafts. The drive shaft 38 for this yam-feed mechanism is coupled by means, including sprocket 42 and chain 43, to the one-time shaft 25 of the complete machine. The capstan drums 1'8 and 39 serve as a common torque amplifier for feeding yarn on demand from any one or more of all spools 19 of the upper tier.

A suitable operating mechanism for each presser-foot 20 is schematically shown in FIG. 3. The lower ends of links 45, 46, are pivotally connected to the respective end of a guide block 47 for the presser-foot. The pin 48 extending from the supporting rod 49 of the pr'esserfoot is received by an arcuate slot 50 in the right-hand or rod-guiding end 51 of lever 52. Intermediate its ends, the lever 52 is pivotally connected at 53 to the link 45. The other end of lever 52 is coupled via link 54 and rocker plate 55 to the biased movable element or armature 56 of solenoid-motor 57 or equivalent. Normally, the resser-foot 20 is out of engagement with the yarn strand S for all angular positions of the parallel-link motion provided by links 45, 46 and their interconnecting guide block 47. The upper end of link 46 is attached to rock shaft 62 which is oscillated under control of the eccentric 58 via cam-follower 59, link 60 and arm 61. The eccentric 58 is attached to and driven by the shaft 34 which is also part of the capstan driving mechanism. To feed a bit-length of the strand S, the solenoid 57 is energized by a command signal at the beginning of a counter-clockwise motion of links 45, 46. The resulting clockwise movement of lever 52 about its pivot 53 lowers the presser-foot 20 into engagement with strand S. Such engagement is maintained until, at the end of the forward or feeding stroke of the presser-foot, the solenoid 5-7 is deenergized as by a limit switch. As later explained in 

